Method for producing a covering

ABSTRACT

A covering is produced by placing a green web including an air-containing fabric layer having a first thickness and a surface layer in a mold having a predetermined shape, and compressing the green web into the predetermined shape such that the air-containing fabric layer and the surface layer unite to each other while the air-containing fabric layer reduces to a second thickness smaller than the first thickness. The resulting compressed green web has a solidity that holds the predetermined shape.

BACKGROUND OF THE INVENTION

This invention relates to a covering such as a floor mat to be placed ona floor portion of an automotive vehicle and the like, and a method forproducing a covering.

There has been known a conventional covering comprising a surface layersuch as a carpet and a backing layer such as a felt which is placed onan underside surface of the surface layer. In such covering, the backinglayer gives an effect of absorbing sound and insulating heat.

The above-mentioned covering exhibits better sound absorbing and heatinsulating effect when being placed on the automotive floor inaccordance with the shape of automotive floor. In an attempt to attainthis purpose, there has been conducted a method of producing thecovering shaped in accordance with the shape of automotive floor: inwhich a base layer of a surface layer (carpet) which is composed of,e.g., latex, polyethylene, polypropylene, vinylchloride, ethylenevinylacetate (EVA) resin and the like is heated with a heater, thesurface layer together with the base layer is compressed and shaped in amold in accordance with the shape of automotive floor, and then, a feltmaterial (backing layer) which has been compressed to attain a certainhardness suitable for absorbing sound and insulating heat is adhered toan underside surface of the carpet, specifically, an underside surfaceof the base layer of the carpet. The above effects can be furtherimproved by attaching additional members such as silencer and heatinsulating member if such high performance of absorbing sound andinsulating heat are to be sought.

However, the above method has been conducted mainly with human labor inwhich workers manually attach the backing layer onto the undersidesurface of the surface layer. This is not favorable in improvingproductivity and rather hinders the idea of enhancing productivity.

Another problem has been involved in the conventional method. Whereasthe surface layer having a proper shape in accordance with the shape ofautomotive floor can be easily obtained according to the moldingprocess, it is difficult to shape the backing layer in accordance withthe shape of automotive floor because the backing layer is made of afelt. Accordingly, complicated and cumbersome manual operations arerequired in attaching the backing layer to the surface layer inaccordance with the shape of automotive floor, lowering efficiency ofattaching operation and resulting in an increase of production cost ofthe covering.

To solve the above problem, generally, the following method shown inFIG. 14 has been carried out. In this method, a backing layer 22 isattached to essential part of a surface layer 21 discontinuously toobtain a covering 20. In other words, the backing layer 22 is attachedto at least some portions of the surface layer 21 where attaching isregarded to be essential in absorbing sound and insulating heat. Thus,efforts have been made to maintain efficiency of producing the coveringat a certain level (avoiding cumbersome attaching operation), whilemaintaining the functions as a covering (sound absorbance and heatinsulation).

However, accompanied by recent demands of seeking comfortable riding inan automotive vehicle, there has been a great demand for higherperformance of absorbing sound and insulating heat. Accordingly, theconventional covering having been partially attached with the backinglayer on the surface layer does not suffice this demand, and an improvedcovering has been demanded.

Also, provision of additional members such as silencer and heatinsulating member raises the production cost and produces a bulkycovering. Accordingly, there is a demand for a covering capable ofimproving the effect of sound absorbance and heat insulation without theprovision of dedicated silencer and heat insulating member.

SUMMARY OF THE INVENTION

In view thereof, it is an object of the present invention to provide acovering and a method for producing a covering which has overcome theproblems residing in the prior art.

It is another object of the present invention to provide a covering anda method for producing a covering having high performance of absorbingsound and insulating heat and high productivity.

One aspect of the present invention is directed to a coveringcomprising: a first layer; and a second layer integrally connectedattached to the first layer, the second layer including a compressedair-containing fabric.

In another aspect of the present invention, at least one of the firstand second layers is made of a thermosetting resin.

In yet another aspect -of the present invention, at least one of thefirst and second layers is made of a thermoplastic resin.

With this construction, since the green web can be easily shaped, thecovering can be shaped exactly in accordance with the shape of a floorof transportation means.

In still further aspect of the present invention, the covering furthercomprises a water proof sheet material between the first and secondlayers.

With this construction, water can be assuredly prevented from beingintruded into the covering.

In yet another aspect of the present invention, the first layer includesa sound absorbable material (silencer).

With this construction, a sound absorbing effect of the covering can beimproved.

In still another aspect of the present invention, the second layerincludes a plurality of air-containing fabrics.

With this construction, the partial use of a fabric suitable to aparticular portion of the covering enables reduction of production costsof covering, while securing the effect of sound absorbance.

It should be appreciated that the use of a plurality of fabrics includesthe use of fabrics different in terms of material and structure.

In another aspect of the present invention, the first layer includes adeodorant material.

In still another aspect of the present invention, the first layerincludes a fabric coated with a deodorant material.

With these constructions, a deodorizing effect can be given to thecovering, as well as effects of absorbing sound and insulating heat. Itshould be appreciated that the deodorizing effect includes fragranceeffect, and the deodorant material includes a deodorizing agent andfragrance agent.

In still another aspect of the present invention, the covering furthercomprises a hook portion.

With this construction, the hook portion of the covering obviatesadditionally mounting a hook to the covering, and accordingly, reducesthe production cost of covering.

The present invention is further directed to a method for producing acovering, comprising: placing a green web including an air-containingfabric layer in a mold having a predetermined shape; and compressing thegreen web into the predetermined shape in such a way that theair-containing fabric layer has a predetermined hardness.

In another aspect of the present invention, the mold includes a pair ofa male member and a female member, and the mold has been heated to apredetermined temperature.

In yet another aspect of the present invention, the mold includes a pairof a male member and a female member, and the green web is heated to apredetermined temperature before the compressing.

In still further aspect of the present invention, the mold includes avacuum device for compressingly drawing the green web onto a moldingsurface of the mold, and the green web is heated to a predeterminedtemperature before the compressing.

In still another aspect of the present invention, the mold includes anair supplier for compressingly supply air onto the green web placed inthe mold, and the green web is heated to a predetermined temperaturebefore the compressing.

According to these methods, the green web can be shaped into thepredetermined shape of the mold (in accordance with the shape of a floorof transportation means such as automotive vehicles), while theair-containing fabric layer being compressed to the predeterminedhardness suitable for absorbing sound and insulating heat. Accordingly,the number of processes required for producing the covering can bereduced, while improving productivity of the covering.

In another aspect of the present invention, the green web furtherincludes another layer, and an adhesive material between the layers.

According to this method, connection between the layers of the green webcan be strengthened. Further, this method is advantageous in the casethat the green web comprises a fabric layer incapable of curing andfusing itself.

In still another aspect of the present invention, the green web furtherincludes a deodorizing layer having a fabric coated with a deodorantmaterial, the fabric being coated with the deodorant material by one ofspraying, roll-coating, and dipping.

In yet another aspect of the present invention, the fabric is coatedwith a solution of the deodorant material, and is heated.

According to these methods, the covering comprising the first layerincluding the fabric coated with the deodorant material is obtainable ina favorable manner.

In yet another aspect of the present invention, the mold is formed witha hook.

According to this method, the hook portion of the covering can be formedat the same time of shaping the covering in the mold, thereby improvingthe productivity of covering.

In further aspect of the present invention, the green web furtherincludes another layer, at least one of the layers being added with anadhesive material of thermosetting resin.

In another aspect of the present invention, the green web furtherincludes another layer, at least one of the layers being added with anadhesive material of thermoplastic resin.

In yet another aspect of the present invention, the green web furtherincludes another layer, at least one of the layers being added with anadhesive material of foam resin.

According to these methods, similar to the case that the green webfurther includes another layer, and an adhesive material between thelayers, connection between the layers can be strengthened. Inparticular, in the case that the adhesive material of foam resin isadded, a flexible and soft covering is obtainable.

These and other objects, features and advantages of the presentinvention will become more apparent upon a reading of the followingdetailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional view of a covering as an embodimentaccording to the present invention;

FIGS. 2A and 2B are diagrams illustrating a method for producing thecovering;

FIG. 2C is a cross sectional view of the covering obtained by the methodshown in FIGS. 2A and 2B;

FIG. 3A is a diagram illustrating an altered method for producing thecovering;

FIG. 3B is a cross sectional view of the covering obtained by thealtered method in FIG. 3A;

FIG. 4A is a diagram illustrating another altered method for producingthe covering;

FIG. 4B is a cross sectional view of the covering obtained by theanother altered method in FIG. 4A;

FIG. 5 is a sectional view of an altered form of covering obtainable bythe method shown in FIG. 4A;

FIG. 6A is a diagram illustrating still another altered method forproducing the covering;

FIG. 6B is a cross sectional view of the covering obtained by the methodin FIG. 6A;

FIG. 7 is a cross sectional view of an altered form of coveringobtainable by the method shown in FIG. 6A;

FIG. 8A is a diagram illustrating yet another altered method forproducing the covering;

FIG. 8B is a cross sectional view of the covering obtained by the methodin FIG. 8A;

FIG. 9A is a diagram illustrating still further altered method forproducing the covering;

FIG. 9B is a cross sectional view of the covering obtained by the methodin FIG. 9A;

FIG. 10 is a cross sectional view of an altered form of coveringobtainable according to the inventive method;

FIG. 11A is a diagram illustrating yet another altered method forproducing the covering;

FIG. 11B is a cross sectional view of the covering obtained by themethod in FIG. 11A;

FIG. 12 is a diagram illustrating a method of applying a deodorizingagent to the covering;

FIG. 13 is a diagram illustrating another method of applying thedeodorizing agent to the covering; and

FIG. 14 is a cross sectional view showing a construction of a coveringof the prior art.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

A preferred embodiment according to the present invention is describedwith reference to the accompanying drawings.

FIG. 1 is a cross sectional view showing a covering 1 embodying thepresent invention. The covering 1 which is to be placed on a floorportion of an automotive vehicle comprises a surface layer 2 such as acarpet and a backing layer 3 which is fixedly attached to an undersidesurface of the surface layer. The surface layer 2 is composed of fabricmade of a thermoplastic resin such as polyester (saturated polyester),vinylchloride, polyethylene, and polypropylene. The covering 1 isfurther provided with a curved portion 4 in the middle thereof, as shownin FIG. 1. The curved portion 4 has an inverted U-shape in cross sectionand corresponds to a tunnel portion in the floor of the automotivevehicle. As shown in FIG. 1, the surface layer 2 comprises a base layer2a and a tuft portion 2b. The tuft portion 2b has a structure of cutpile, but may have a structure of loop pile.

The backing layer 3 is composed of an air containing fabric layer madeof a thermoplastic resin such as polyester. The backing layer 3 isfixedly attached to the surface layer 2 substantially over its entiretyin a compressed state to attain a certain hardness suitable forabsorbing sound and insulating heat. It should be appreciated thatopposite ends of the surface layer 2 (right and left sides in FIG. 1)are compressed to a certain extent and are formed into a thin plate-likeshape.

The covering 1 having the above construction is produced according tothe following method. As shown in FIG. 2A, the surface layer 2 andbacking layer 3 each in a form of sheet are placed one over the other toform a double-layered member (hereinafter referred to as a "green web").The thus formed green web is placed on a lower mold (male mold) 11 whichis heated at a specified temperature in advance. Thereafter, an uppermold (female mold) 10 is lowered to enclose the green web inside theupper and lower molds (see FIG. 2B), and the green web is pressurized ata specified pressure for a predetermined time period. Thereby, thesurface layer 2 and the backing layer 3 are fused to each other in thepressurized heated state and shaped into a specified form. Thus, thecovering 1 is produced, while the backing layer 3 is compressed toattain the certain hardness (see FIG. 2C).

In this embodiment, the covering I having high performance of absorbingsound and insulating heat was obtained using the surface layer 2 (300g/m²) and backing layer 3 (1000 g/M²) each made of polyester fiber in astate that the upper mold 10 and lower mold 11 are respectively kept ata temperature in the range of 40 to 140° C. and in the range of 145 to230° C. and the surface layer and backing layer are pressurized under apressure of 0.5 to 5 kg/cm² for 15 to 30 seconds.

Since being made of a thermoplastic resin and thus feasible in shaping,the backing layer 3 can be evenly attached to the underside surface ofthe surface layer 2 over its entirety, as shown in FIG. 1, while beinguniformly compressed in the molds. Accordingly, the covering 1 with thebacking layer 3 evenly attached to the surface layer 2 can attain highperformance of absorbing sound and insulating heat, compared to theconventional covering in which the backing layer is discontinuously(unevenly) attached.

Further, as mentioned above, the surface layer 2 and the backing layer 3are compressingly shaped into a specified form by compression molding ina state that the surface layer 2 is placed over the backing layer 3.Thereby, the surface layer 2 and the backing layer 3 are integrallyconnected to each other, while being shaped into the specified form. Atthe same time when fusing the surface layer and the backing layer, thebacking layer 3 is compressed to attain a certain hardness. Accordingly,in the present invention, the processes of shaping the surface layer,compressing the backing layer, and attaching the backing layer onto thesurface layer can be performed at the same time, whereas, in theconventional method, these processes are conducted individually.

The above method according to the present invention remarkably reducesthe number of processes required for producing the covering 1, therebyimproving productivity of the covering. In particular, the conventionalproduction method has faced the complicated and cumbersome attachingoperations in an attempt to obtain the backing layer having the shapeidentical to the surface layer. However, the inventive production methodcan obviate these cumbersome and complicated attaching operations.Accordingly, the inventive method is advantageous in improving theproductivity of covering.

In the foregoing embodiment, the backing layer and surface layer areplaced one over the other in shaping the green web by the moldingprocess. Alternatively, the surface layer 2 and the backing layer 3 maybe adhered to each other prior to the shaping.

In the foregoing embodiment, the covering 1 is obtained by, e.g., hotpress molding in which the surface layer 2 and the backing layer 3 arecompressed and shaped in a heated mold. Alternatively, the covering 1may be obtained by e.g., cold press molding in which a green web ofsurface layer 2 and backing layer 3 is heated with a heater in advance,and then, the heated green web is compressed and shaped in a mold.

Alternatively, other than the above-mentioned compression molding,so-called "vacuum forming" and "air pressure forming" can be conductedto produce the covering 1. Specifically, in the vacuum forming, a greenweb of surface layer 2 and backing layer 3 is heated with a heater andthen shaped by being pressingly brought into contact with the upperfemale mold 10 or lower male mold 11, while drawing the air between theupper (lower) mold and the green web by a vacuum pump. In the airpressure forming, a green web of surface layer 2 and backing layer 3 isheated with a heater and then shaped by being pressingly brought intocontact with the upper (lower) mold, while being pressurized with airbeing blown onto the green web.

Further, the covering 1 can take various alterations other than theaforementioned embodiment, and some of the alterations are brieflydescribed hereafter. These alterations can also be shaped by vacuumforming or air pressure forming. For the sake of convenience on thedescription, however, the following alterations are to be produced bythe compression shaping.

First Alteration

The first alteration is such that the covering 1 is formed with hooks 4aand 4b at opposite ends thereof to be hooked with a floor portion of anautomotive vehicle, as shown in FIG. 3B, with use of upper (female) mold10a and lower (male) mold 11b shown in FIG. 3A.

This arrangement not only obviates provision of additional hooks to thecovering 1 but is advantageous in that the hooks 4a and 4b can be formedat the same time of compression shaping of a green web comprising thesurface layer and backing layer. Accordingly, the production cost can befurther reduced, and productivity can be improved.

In forming the hook 4a (4b), it may be preferable to separately providea mold (hook mold) for forming the hook in a mold main body so that thehook mold can be heated at a higher temperature so as to acceleratecuring of the hook 4a (4b). With this arrangement, the hooks 4a and 4bof greater strength can be obtained.

Further, it may be preferable to additionally provide a plate-likemember which has a specified dimension and is made of a thermoplasticresin such as polypropylene or a thermosetting resin such as uncuredphenol impregnated felt, to the green web in compressingly molding thegreen web. With the provision of plate-like member, the hooks can beintegrally formed with the covering.

Second Alteration

In this alteration, as shown in FIG. 4A, a silencer 5 in a form of sheetand made of polyvinyl chloride is interposed between the surface layer 2and the backing layer 3. In a state that the silencer 5 is sandwichedbetween the layers 2 and 3, a green web of surface layer and backinglayer is compressingly shaped in a mold which is heated at apredetermined temperature in advance. Thereby, as shown in FIG. 4B, acovering 1a having higher performance of absorbing sound is obtained.

Alternatively, other than the above method of interposing the silencer 5between the surface layer 2 and the backing layer 3 and shaping thegreen web of surface layer and backing layer together with the silenceraccording to the compression shaping, the following methods can beadopted. Specifically, the silencer 5 may be placed at an undersidesurface of the backing layer 3, and the green web of surface layer andbacking layer may be shaped according to the compression molding toproduce a covering 1a' shown in FIG. 5. In this case, also, the covering1a' having higher performance of absorbing sound can be obtained.

Third Alteration

As an alteration of the covering shown in FIG. 4B, a covering 1b can beproduced in the following manner. As shown in FIG. 6A, pieces ofsilencers 6 are arranged side by side between the surface layer 2 andthe backing layer 3, and a green web of surface layer and backing layerwith the silencers 6 interposed therebetween is shaped according to thecompression shaping in a mold which is heated at a predeterminedtemperature in advance. Thus, the covering 1b shown in FIG. 6B can beobtained.

With this arrangement, the covering 1b having higher performance ofabsorbing sound can be obtained. Further, the provision of silencers 6reduces the production cost of covering. Alternatively, the silencers 6may be placed on the underside surface of the backing layer 3, and thegreen web of surface layer and backing layer together with the silencersis shaped according to the compression molding, thereby producing acovering 1b' shown in FIG. 7.

Fourth Alteration

As shown FIG. 8A, a backing layer 7 composed of fabric layers 7a and 7bwhich are different in fabric material from each other is placed at anunderside surface of the surface layer 2 to form a green web, and thegreen web is compressingly shaped in a mold which is heated at apredetermined temperature in advance, thereby producing a covering 1cshown in FIG. 8B.

In this case, the fabric layers 7a and 7b are respectively made ofpolyester fiber and polyethylene fiber, both of which can be obtained ata relatively low cost. Accordingly, the production cost of coveringcomposed of these inexpensive materials can be effectively reduced.Instead of using fabric of polyester and polyethylene fiber, an aircontaining fabric may be applicable. Since the air containing fabric canalso be obtained at a low cost, the production cost of covering can alsobe reduced.

Further, a plurality of fabric layers excellent in absorbing sound maybe placed one over another to produce a covering. Thereby, the coveringexcellent in absorbing sound can be produced without using a silencer.It is possible to obtain a light-weighted covering with such fabriclayers provided therein, compared to the case where the covering isprovided with a silencer in attaining the same sound absorbance level.

Fifth Alteration

As shown in FIG. 9A, a plurality of strip-like fabric layers 8a and 8bare connected to one another in patchwork manner in a widthwisedirection of the surface layer to form a backing layer 8. The thusformed backing layer 8 and surface layer 2 are placed one over the otherto form a green web, and the green web is shaped in a mold which isheated at a predetermined temperature in advance according tocompression molding. Thereby, a covering 1d shown in FIG. 9B can beproduced.

In this case, one of the fabric layers 8a and 8b constituting thebacking layer 8 may be a fabric obtainable at a relatively low cost.Thereby, the covering 1d can be produced at a lower cost, as well as thecovering 1c shown in FIG. 8B. Further, in the case where the covering isrequired to partially have high performance in absorbing sound andinsulating heat, the covering may be provided with fabric layers made ofa material of high sound absorbance and heat insulation at portionsrequiring such high performance. Thus, a covering exhibiting highperformance of sound absorbance and heat insulation can be produced,while suppressing the production cost.

Various coverings described with reference to FIGS. 1 to 9B are producedin such a manner that the surface layer 2 and backing layer 3 are bothcomposed of fabric made of a thermoplastic resin. Alternatively, thesurface layer 2 and backing layer 3 may be composed of fabric made of athermosetting resin. In this case, it is desirable to set a temperatureat which a mold is to be heated low to suppress a drastic curing of thesurface layer 2 and backing layer 3 as much as possible.

Further, besides the case that the surface layer 2 and backing layer 3are made of the same resin, the surface layer 2 and backing layer 3 maybe formed of a fabric made of resins different from each other, e.g.,thermoplastic resin and thermosetting resin. In this case, a temperatureat which the mold is to be heated is minutely adjusted.

In the case where an automotive floor on which the covering is to beplaced has a relatively simple configuration, it is possible to form thesurface layer 2 or backing layer 3 of natural fiber.

In this case, compared to the case where both the surface layer 2 andbacking layer 3 are composed of fabric of thermoplastic resin and/orthermosetting resin, an adhesion strength of the surface layer 2 andbacking layer 3 is liable to be lowered. To reinforce the adhesionstrength, a sheet material made of a thermoplastic resin, thermosettingresin, and resin containing foaming agent, powder made of these resins,or joint medium of fabric fiber may be provided on a joint surface ofthe surface layer 2 and backing layer 3. Thereby, the surface layer andbacking layer can be connected to each other assuredly in compressionmolding.

Alternatively, resin powder and joint medium of fabric fiber may bedirectly provided on one or both of the surface layer 2 and backinglayer 3, or fiber of low melting point may be mixed in fabricconstituting the surface layer 2 and backing layer 3.

The use of resin containing foaming agent is advantageous in enhancingflexibility and softness of covering as well as the effect of joint.

The use of joint medium is not limited to the case that natural fiber isused in the surface layer and backing layer, but applicable to, e.g.,the case that the surface layer and backing layer are composed of fabricmade of a resin. For example, if the surface layer and backing layer arecomposed of fabric made of resins different from each other, the meltingpoint of resin used in the surface layer is different from the backinglayer. As a result, a desirable adhesion strength cannot be obtained infusing the surface layer and backing layer. In such case, the jointmedium is effective in assuredly connecting the surface layer andbacking layer.

A covering of the present invention can take any form other than theabove mentioned embodiment and alterations according to needs.

For instance, a covering having combined features of the coverings 1 to1d shown in FIGS. 1 to 9B is obtainable. Specifically, the coverings 1cand 1d in FIGS. 8B and 9B may be provided with the silencer of thecoverings 1a, 1a', 1b, 1b' to produce a covering excellent in absorbingsound.

Besides the above coverings, a film composed of polyethylene orpolypropylene or a plastic sheet may be placed between the surface layer2 and backing layer 3. Thereby, water can be prevented from intrudinginto the backing layer 3, and a waterproof covering can be obtained.Alternatively, the surface layer 2 or backing layer 3 may be mixed withfiber capable of repelling water, thereby preventing water intrusion.

Further, an auxiliary material 3' composed of air containing fabric maybe placed between the surface layer 2 and backing layer 3 or at anunderside surface of the backing layer 3, and a green web of surfacelayer and backing layer together with the auxiliary material 3' isshaped to a specified form according to compression molding. Thereby, acovering 1e having a greater thickness at portions other than the curvedportion 4 can be obtained, as shown in FIG. 10. The covering 1e isadvantageous when a greater thickness is required at some portions ofthe covering in accordance with the shape of automotive floor, orpartially attaining higher effect of sound absorbance and heatinsulation is demanded.

The covering in the foregoing embodiment and alterations basically has amulti-layered structure of surface layer 2 and backing layer 3. However,a covering according to the present invention is not limited to themulti-layered covering, but a single-layered covering can attain thesame effect as the multi-layered covering.

Specifically, as shown in FIG. 11A, an air containing fabric layer 12composed of a thermosetting resin or thermoplastic resin is shaped intoa specified form, while being compressed to attain a certain hardness bycompression molding. Thereby, a single-layered covering 1f shown in FIG.11B can be obtained.

In this case, also, the silencer may be placed to give an effect ofgreater sound absorbance to the covering. Alternatively, various kindsof air containing fabric layers used in the backing layers 7 and 8 shownin FIG. 8B and 9B may be used to produce a covering at a low cost.

Further, a shape of covering, fabric material composing the surfacelayer and backing layer, or conditions for molding can be arbitrarilyselected so as to obtain a favorable covering according to needs. Forexample, the following is a list of materials suitable for the fabriclayer: chemical fiber, inorganic fiber, metallic fiber, natural fiber,mixture thereof, and any fiber mixed with thermoplastic resin,thermosetting resin, adhesive agent, flame retarder (flame retardantfiber), deodorizing agent (deodorizing fiber), water repelling agent(water repelling fiber), antibacterial agent (antibacterial fiber),so-called "Chameleon" fiber for producing "Chameleon" fabric and thelike.

In particular, in the case where an antibacterial effect is to beapplied to the covering, an antibacterial agent is coated to the backinglayer 3 or silk printing is conducted thereto.

The structure of fiber is also not limited to the above, and anystructure of fiber may be applicable according to needs. Further, thesurface layer 2 and backing layer 3 have the same dimension in width,e.g., as shown in FIG. 2A. However, the backing layer 3 may have a widthsmaller than the surface layer 2, and a green web of these layers iscompressingly shaped according to compression molding.

A sheet member composed of paper, resin or elastic material may beinterposed between the surface layer 2 and backing layer 3. Thus, highersound absorbance can be attained by actively lowering air permeability.Alternatively, instead of interposing the sheet member between thesurface layer 2 and backing layer 3, a plurality of backing layers 3 maybe prepared and a plurality of sheet materials may be interposed amongthese backing layers 3.

Though not shown, there may be provided between the surface layer 2 andbacking layer 3, a sheet member made of fabric and containing activatedcarbon therein, deodorizing sheet member containing therein activatedcarbon, activated clay, zeolite, deodorizing fiber and the like,deodorizing sheet member containing therein metallophthalocyanine andplant extract, or sheet member coated with a fragrant agent. Thereby, adeodorizing and fragrance covering is obtainable.

The deodorizing sheet member can be obtained by constituting a sheetmember of fabric made of deodorizing fiber or coating a deodorizingagent to a sheet member. Some methods for deodorizing a sheet member aredescribed hereafter.

FIG. 12 shows a spraying method in which a deodorizing solution issprayed onto a surface of a sheet member 14 with a spray 16 as the sheetmember 14 being transported on a conveyor roller 15. The deodorizingsolution is obtained by dissolving a deodorizing agent composed of plantextract and the like in water and a solvent other than water.

FIG. 13 shows a so-called "roll-coating" method in which one of rollers17a and 17b (in the drawing, roller 17a) is partially immersed in acontainer 18 containing a deodorizing solution therein, and the sheetmember 14 is transported between the rollers 17a and 17b in contact withthe rollers 17a and 17b in accordance with a rotation thereof. Accordingto this method, as the sheet member 14 is transported forward, thedeodorizing agent is coated to the sheet member 14 in contact with theroller 17a which is partially immersed in the container 18.

Further, though not shown, dipping method can be conducted in which asheet member is dipped in a container containing a liquid-typedeodorizing agent. The sheet member having been coated with thedeodorizing agent according to the dipping method is heat-dried andtransported to a press section. For example, the sheet member with thedeodorizing agent coated thereon is transported to a hot press sectionto be heat-dried and pressed, or first transported to a heating sectionto be heat-dried and then to the press section to be pressed.

In the foregoing embodiment and alterations, a covering according to thepresent invention is to be placed on a floor portion of an automotivevehicle. However, the inventive covering may be used for a door, trunk,ceiling, rear package, seat trimming, etc. of automotive vehicles, andany transportation means other than the automotive vehicles, e.g., shipsand airplanes. Furthermore, the inventive covering may be adaptable fora ceiling, wall, floor, sofa and the like used in buildings such ashouses, factories, and stores.

Although the present invention has been fully described by way ofexample with reference to the accompanying drawings, it is to beunderstood that various changes and modifications will be apparent tothose skilled in the art. Therefore, unless otherwise such changes andmodifications depart from the scope of the present invention, theyshould be construed as being included therein.

What is claimed is:
 1. A method for producing a covering,comprising:placing a green web including an air-containing fabric layerhaving a first thickness and a surface layer in a mold having apredetermined shape; and compressing the green web into thepredetermined shape such that the air-containing fabric layer and thesurface layer unite to each other while the air-containing fabric layerreduces to a second thickness smaller than the first thickness, thecompressed green web having a solidity that holds the predeterminedshape, wherein the mold includes a pair of a male member and a femalemember, and the mold has been heated to a predetermined temperature. 2.A method for producing a covering, comprising:placing a green webincluding an air-containing fabric layer having a first thickness and asurface layer in a mold having a predetermined shape; and compressingthe green web into the predetermined shape such that the air-containingfabric layer and the surface layer unite to each other while theair-containing fabric layer reduces to a second thickness smaller thanthe first thickness, the compressed green web having a solidity thatholds the predetermined shape, wherein the mold includes a pair of amale member and a female member, and the green web is heated to apredetermined temperature before the compressing.
 3. A method as definedin claim 2, wherein at least one of the layers includes an adhesivematerial comprising thermosetting resin.
 4. A method as defined in claim2, wherein at least one of the layers includes an adhesive materialcomprising thermoplastic resin.
 5. A method as defined in claim 2,wherein at least one of the layers includes an adhesive materialcomprising foam resin.
 6. A method for producing a covering,comprising:placing a green web including an air-containing fabric layerhaving a first thickness and a surface layer in a mold having apredetermined shape; and compressing the green web into thepredetermined shape such that the air-containing fabric layer and thesurface layer unite to each other while the air-containing fabric layerreduces to a second thickness smaller than the first thickness, thecompressed green web having a solidity that holds the predeterminedshape, wherein the mold includes a vacuum device for compressinglydrawing the green web onto a molding surface of the mold, and the greenweb is heated to a predetermined temperature before the compressing. 7.A method for producing a covering, comprising:placing a green webincluding an air-containing fabric layer having a first thickness and asurface layer in a mold having a predetermined shape; and compressingthe green web into the predetermined shape such that the air-containingfabric layer and the surface layer unite to each other while theair-containing fabric layer reduces to a second thickness smaller thanthe first thickness, the compressed green web having a solidity thatholds the predetermined shape, wherein the mold includes an air supplierfor compressingly supply air onto the green web placed in the mold, andthe green web is heated to a predetermined temperature before thecompressing.
 8. A method for producing a covering, comprising:placing agreen web including an air-containing fabric layer having a firstthickness and a surface layer in a mold having a predetermined shape;and compressing the green web into the predetermined shape such that theair-containing fabric layer and the surface layer unite to each otherwhile the air-containing fabric layer reduces to a second thicknesssmaller than the first thickness, the compressed green web having asolidity that holds the predetermined shape, wherein the mold is formedwith a hook.